Condensate Management

If condensate is not removed from the compressed air system it will have an adverse impact on process equipment and tools causing corrosion of pipework and receiver vessels, possibly blocking valves and causing sensitive air controlled instrumentation to malfunction. These problems can be expensive to repair and can lead to loss of process and production. Failure to remove condensate efficiently also puts a strain on air dryers and purification equipment increasing maintenance frequency and cost. In addition, compressor condensate contains up to 5% oil and can't be discharged to the environment without purification.

Traditionally design engineers have specified manual valves or time controlled solenoid drains as a solution for removal of condensate from compressors, receivers and filter housings. These solutions do work however the manual valves require a strict maintenance regime and they often become a forgotten part of the process leading to the build-up of condensate. Both manual valve and time controlled solenoid valves lose compressed air when the condensate is drained off and over the life cycle of the compressed air system the cost of the wasted compressed air can become significant.

Safewell supplies the full range of Donaldson Ultramat UFM-T condensate drain valves. These valves are zero loss drains which mean they do not waste compressed air when operating and, therefore, conserve energy and reduce operating costs. Typical payback is less than six months.

Condensate is removed from the compressed air system by automatic drains which discharge the condensate. Condensate contains up to 5% oil (50,000 parts per million or mg/litre) and can't be discharged to the environment (foul drains) without purification. Typically waste water discharged to the municipal drainage system or directly to the environment has to meet the local regulatory body compliance levels which will be stipulated in a legal consent to discharge. For discharges to the foul drain the typical maximum level of oil based hydrocarbons is 100 parts per million (100mg/litre) although this can be much lower according to the local infrastructure and specific environmental concerns.

Safewell has considerable experience in the design and implementation of industrial waste water treatment systems. We can visit your site to review your requirements and then offer a full technical solution including supply, installation and commissioning. For the treatment of compressor condensate, we offer the proven oil / water separator technology manufactured by Donaldson Filtration Solutions.

The Ultrasep UFS-SP N range includes 7 sizes ranging from nominal compressor capacities from 120m3 / hour to 7200 m3 / hour and will ensure that your compressor condensate is treated in accordance with legal discharge guidelines. In situations where a stable emulsion has been formed the Ultraaqua product, may be required. This product guarantees a final water quality of less than 5 parts per million hydrocarbon.